Wire forming apparatus



July 12, 1960 R. CALMY WIRE FORMING APPARATUS 3 Sheets-Sheet 1 Filed Aug. 29, 1955 INVENTOR. BY]? a I 11 C'a 1m 5/- l 23 025.? HZ' July 12, 1960 CALMY WIRE FORMING APPARATUS s She'ts-Sheet 2 Filed Aug. 29, 1955 INVENTOR. Ra I 11 Ca [m BY July 12, 1960 R. CALMY 2,944,584

WIRE FORMING APPARATUS Filed Aug. 29, 1955 3 Sheets-She et 3 IINVENT'OR.

Un fi d W Paw-*0 pertains particularly to apparatus .for forrningwire of sub stantial gauge into spirals which maybe intermeshed with each other to form a continuous wire screen.

In making fireplace screens and like products -it heretofore has been the practice to pass wire of. substantial gauge through a die which forms it into a spiralot'pre determined pitch. When the. spiral has reached the desired length, the apparatus isstopped and the spiral-is cutoff.

' The spiral then is held in suitable apparatus and placed in such a position that upon passing a further quantity of wire through the die theresulting second spiral is inter meshed a'sit leavesthef die with the first spiral. [When thel'sec'ond spiral has reachedthe selected length,'it also is' cut off. .This process is repeated until ascreen of the desired dimensions has been built up. I

, Numerous difiiculties are, however, inherent in the I I v In-the first place means have not been available for arresting thejpassa'geof the above described procedure.

wire through the die at the precise instant when the selected length ,of wire has passed through it. As a consequence, the spiral units of .which the screeniscomposed are of unequaljlength' and mustbe trimmed. f ave ously is a time consuming and wasteful operationf Also, eflicient means have not been available 'fojr'jad-v justin'g thewii e' forming apparatus so that it; canproduee -spirals of'a 's'elected length over a wide range of lengths,

f The manner in which the foregoing and other objects of this invention are accomplished will be apparent from theaccompanying spec'ificationand claims, consideredfltogether with the drawings, wherein:

Fig. l is a viewin side elevation of the herein de-' scribed wire forming apparatus; 1 1

Fig. 2 is-an enlarged fragmentary'view, partly in section, of the die used in the herein described wire forming pp :1

Fig. 3 is a sectionalview, taken along line 33 of Fig.2; m

Fig. 4 is a detail, fragmentary view in section illustrating means which may be employed' for opening and closing the cooperating drive rollsemployed for feeding wire through the herein described apparatus;

Fig. 5 is a detail view in elevation of mechanism-which maybe, employedin determining the lengthiofthe spiral sections formed by the presently described apparatus; and Fig. 6 is a circuit diagram illustrating-a circuitwhich may be employed in the control of the apparatus.

Generally stated, the herein described wire forming apparatus comprises die means dimensioned for forming wire into a. spiral of -the desiredpitch when the wire is forced through the die." Drive means are provided for driving the wire through the. die means; Drive. control means also areprovidedfor arresting or otherwise afiectingthedrive means when a predeterminedlengthof wire Still furthenthe dies which have been employed in 'apparatus 'of this ",class have been subject to mutilation and rapid wear by the; actio'npof heavy gauge wire passing rapidly throughjthemi j Accordin ly," is th", ob tl f the present invention to provide wire f rmin japparatus, characterized y n following jobjectsiand' advantages: Fi st, it a ures accu at y, the length pr .each. spiral formed, e iminat ng. a j ubs'tant mm ng waste. secqnili a e diu t iea ndir pid yle' 'i r s ans of anydesired length betweei wide s Third, it is several times more'rapid in operation than is prior art apparatus of -this class.

which it handles i ea 1 .adiu bl fi 1 t iami e t e. w

1 I i i iq h. the a para u t t s rfilq q qhoperation,

S.eventh, it provides means for holding a formingdie has bGBnIfotrned intoaspiral. V

. Also, means are providedror. adjusting the drive means to ,enablezthreading wire 'throughthe apparatus at the start of each operation Withfacility. Further, means are provided for adjusting the drive controlmeansso that the length of the spiral sections may be varied between wide limits simply and easily. Still further, a. die is provided which includes means'for minimizing the wear attendant upon passing heavy-gauge wire through the die at high -velocity.

Considering the foregoing greater detail and particular referenceito the drawings:

The driveunit for the herein"described wire forming 'apparatusis mounted on a jframe 'indicatedat 10. A

motor12 is mounted at the baseoftheframe; Its shaft mounts-apulley 14' which carriesabelt 16, which, in turn, drives'apulley' 18 on'clutch '20. CIutQh ZQmayLbeof conventional construction and isoperated by means of "securely which means, however, areeasilyadjustable for "wire gauge,-spiral pitch, etc. p 7 E g th, i Pre ew m s q m iz ae t "diejcaujsed by passage of the wire therethroughL zgesr nw, Y, l. -""Te'nth, it is attachable to, "and ope'rableiin conjunction with,,wo rk holding apparatus of the class commercially Wee a a a l b lwaria l s e i fi ethe i the rmdue a l rs ne or te a n fl s a re ed" by ch es Nin i 1 fi s nu w a lthe wire 'usj ii a o m a clutch collar 22. r 3 K drive: shaft 24 is mounted in bearing s 26;28' and is driveriythrofighclutch Z0. This shaft 'drivesithefeding means .forforcingthe wirethroughthe forming die. T o thisfend it has rigidly aflixedto it a gear 30 which? drives a secondarydrive 'shaftfiz'thro'ugh themeshingf'gear 34. Shaftv 3Z ismountedifor rotation in self aligning: bear;

;in'gs.36,z-38.1 Bearing 36 is mounted on an eiZtensiOn 40 of frame 10. Bearing 38 is mounted in. a-block 42 :wh;ich in turn is'slidablyimounted in' Er slot 43 (=Figfi4) in'the from frame member, thereby floating the bearingunlesfs it is locked in positioniby suitableimeans. Shafts 24, 32 carry af'their respective forward ends drive wheels 44, 46. Wheelf44has in its peripheralsurface a pain of spaced. grooves-48; 50'while wheel 4'6Yhas in its peripheral surface a corresponding" pair'fof spaced grooves-52,54. v l

As is apparentrparticularly from Fig. -2, the-peripheral surfaces of,wheels.44, 46 are closely adjacent eachiother and .groovesr48, 50 in the.upper wheel are aligned .and

in substantial registration with grooves 52,554 'in'the lower wheel. Also, since a one to one gearratio may be present between gears 30, 34, thewheelsrotate at identical speeds. Accordinglvawire 56 maybe fed through a,

Patented July 12, l960 suitable wire guide 58, lubricated with oil through conduit 60, fed between wheels 44, 46, and driven thereby through a die to be describedhereinafter Means also are provided for separating drive wheels 44, 46 in order to feed a wire therebetween with greater facility at the start of each operation. In the illustrated embodiment, such means comprise'a cam 62 illustrated in Fig. 4. I

Cam 62 is mounted ori'a shaft 64 supported between frame extensions 66, 68. It is operated by means of a lever 70 which is r'eleasably connected through spring 72 with another frame extension 74. The working surface of cam 62 engages a pin 76 which is slidable in an opening through frame member 78, and which abuts against the upper surface of block 42. As has been indicated above, this block is slidably mounted in opening 43 of frame 10 and carries the self-aligning bearing 38 by means of which due end of secondary drive shaft 32 is supported.

Block 42 in turn is supported through a compression spring 80, one end of which presses against the lower surface of block 42 and the other end of which presses against the frame of the apparatus. Accordingly, during normal operation of the apparatus, lever arm 70 is in a depressed position as indicated in solid outline in Fig. 4. It is held resiliently in this position by the action of spring 72.

When it is desired to separate feed rolls 44, 46, as when introducing wire therebetween, one end of spring 72 is released from the member to which it is attached, whereupon lever arm 70 assumes the ddtted outline position of Fig. 4. In this position the action of cam 62 permits elevation of block 42, and hence of feed roll shaft 38 which it supports, through the action of compression spring 80. Wire 56 then may be threaded between the rolls and positioned in a selected opposed pair of peripheral grooves 4854. Thereafter lever 70 may be returned to its Fig. 4 full outline position and spring 72 reconnected to it. The drive wheels then are ready for feeding wire through the apparatus.

The drive control As has been indicated hereinabove, it is one of the primary features of the presently described wire forming apparatus that its operation can be adjusted to form accurately predetermined lengths of spiraled wire over a wide range of spiral lengths. The means for accomplishing this purpose are illustrated in Figs. 1, and 6. In general, they comprise means for arresting the motion of drive. wheels 44, 46 after a predetermined operation thereof.

To this end there is provided on drive shaft 24 a gear 90. This gear meshes with a gear 92 carried by shaft 94 of gear box 96. Gear box 96 is supported on the frame of the, apparatus and is of the class by means of which a stipulated rate of rotation of shaft 94 may betranslated intoany desired rotational speedof gear boxshaft 98. Shaft 98 then is used to operate means for arresting the motion or the drive wheels.

Such' means may include a cam 100 having on its surface a projection 102 (Fig. 5.). As the cam is rotated by shaft 98, its surface engages. a wheel 104 carried by a spring pressed plunger 106 of an electric switch 108. Switch 108is in an electric circuit with a solenoid 110, which also is mounted on the frame of the apparatus. This circuit is illustratedin Fig. 6. Electric power from termine the length of the spiral sections formed by the apparatus.

Energization of solenoid 110 may be used for arresting the motion of the drive rolls, suitable means for accomplishing this purpose being as follows:

A link 120 interconnects the solenoid 110 with one end of a latch member'122. The other end--of the latch member is pivotally connected to frame 10 through pin 124. "An arm l26 e'xtends" outwardly from the latch and abuts against a stop 128'. A compression spring 130 is interposed between frame member 10 and arm 126 to urge the arm, and hence'latch122, in a counterclockwise direction as viewed in Fig. 1. This action is opposed and overcome by the action of solenoid 110 when it is energized. Hence the latch is shiftable between two positions and this, motion may be used for engaging and disengaging clutch 20.. t

Various linkages may be employed for achieving this result. In the illustrated linkage, a foot lever 132 is pivotally mounted intermediate its ends on a frame extension 134. The rear end of this lever is pivotally connected .to link 136 which in turn is pivotally cdnnectedto link'138. The upper end of the latter link is pivotally connected to one arm 140 of a bell crank lever 142; The other arm 144 of the bell crank lever is connected to clutch collar 22, by means of which the clutch is operated.

A spring 146 interconnects arm 144 and frame memher 148.. 22 continuously and resiliently to the right as viewed in Fig. 1, this being the position of clutch disengagement.

A cross link 150 is pivotally connected at one of its ends to link 138 and adjacent the other of its ends to one of the frame members. A projecting segment of the cross link is formed with a notch 152 dimensioned for reception of latch 122.

Thus when foot lever 132 is depressed until it reaches the operating position of Fig. 1, links 136, 138 are elevated, moving arm 144 of bell crank lever 142 clockwise and engaging clutch 20. At the same time, the notched end 152 of cross link 150 is lowered to a position wherein spring 130 will advance latch 122 into engagement with the notch, solenoid 110 being de-ener- 'gized. I

After cam 100' has made one complete revolution, sole noid '110 'will be energized. Thereupon, acting through rod 120, it withdraws latch 122 from engagement with the notched end of cross link 150; This'enables spring i.e. the actions occurring upon completion of an operata'suitable source passes through line 112, switch 108,

line 114, solenoid 110, and return line 116. A master switch 118 also may be included in parallel in the circuit, for turning the solenoid on and off and for use in emergency.

Accordingly, solenoid may be energized by the action of cam 100 after a time interval determined by the setting of gear box 96. This timing in turn will doing cycle and disengagement of latch 122, are indicated by the'arrows in Fig. 1. I

7 7 V o :The die Positioned adjacent drive wheels 44, 46 at the outfeed side thereof is the die assembly indicated generally at 160. 'The construction of this assembly is illustrated in detail in Figs. 2 and 3 It comprises a housing 162 having extending outwardly therefrom a plug 164 dimensioned-to fit into an opening inone of the members comscrew "It is drilled to provide two spaced, longitudinal channels 172, 174. The spacing between these channels is such that they register with the opposed channels 48-54 ondrive wheels 44, 46.

Casing 168 has therein a longitudinal recess dimensioned to receive a die180, which is secured in the casing by means of set screw 182. The die is cy'lindrical in Its action is such as to urge clutch collar,

v a die;

' shape and has on its peripheralsurface.spirallyj formed channels 184, 186. These aredimensioned to receive slidably wire oftheselected gauge. Their infeed terminals register 'withchannels 172, 174 through 'the'casing.

Since there is a very substantial thrust developed; by

the wire as it is forced through the die assembly,-means are provided to protect thecomponent -membersfof the assembly from wear and abrasion as well as to protect the wire itself from mutilation. Such means include a bearing collar or sleeve 190 contained in the outer pormo "entumflto carry pro ection on cam 100'pasti miller;1 04, ,ige. totheiposition of Fig.1. 5, whereit is ready.

tion of the recess in housing 162and rotatably mounted about die 180. Its inner end abuts the end of die holder 168. Its outer end abuts against a hollow keeper or retaining member 192. The latter in turn is supported adjustably by means of a bracket 194 attached through.

adjustment slot 196 to housing 162-by means of bolt 19,8.

Accordingly when a new die is to be inserted in the apparatus, it is secured in die holder 168, its outer. end

encircled with hearing collar 190, and keeper. 192 ap- V plied snugly but without preventing rotation'of thecollar. Then when wire is passed through the die, it engages the inner surface of bearing collar 190' with considerable force, causing the collar to rotate at a'speed deter-mined by the speed of movement of the wire. As a consequence,

. mounted in the housing and having a forward .longitudiwear on the die assembly and mutilation of the wire are kept at a Operation The operation of the herein described :Wil'e forming apparatus is as follows: I

raise shaft 32, and hence separate wheels 44, 46. Wire 56 then is fed between thewheels along a path defined by selected channels 48-54 in thewheels, openings 172, 174 in the die holder 168, and channels 184, :186 indie body 180. Lever 70 then is depressed and maintained resiliently in position by attaching an end of'spring 72 V to it.

tor 12 started. The motor runs continuously, driving shaft 24 through clutch 20. Footrlever 132 then-is depressed. This engages clutch 20 and initiatesrotation Gear box 96 next is set at the desired ratio and mo to; ,startfanqtherl cycle;

paratus infwhich. it is contained untilthe of the spiralis substantially aligned with die 180. v A' second. cycle of operation is'initiated by depression of footlever 132 whereupon another length ofwireis formed into spiral of identical length and pitch to'jthe first length.

In addition, it is inter-meshed with the first length as itjis formed so that a section of screen or :wire mesh is builtl up. "This process, is repeated as often'as is necessary to give a final screen" 202 of the desired dimensions.

Hence it is ,apparent that by the present invention 'I have provided wire forming apparatus which forms wire into "spiralsof selected length and predetermined pitch rapidly and accurately. In addition, the length of the spiral produced may be easily'adjusted over a widerange by suitable adjustment of the drive, and its pitch readily varied by exchanging dies. Also, the spirals are formed without excessive wear on the die and without mutilation of the wire of which the spirals are. composed.

Having thus described my invention in preferred em 7 bodiments, I claim:' a a 1. Wire forming apparatus comprising a frame, a die assembly on the frame comprising a housing, a die holder nal bore and a rearward closed end portion, awire receiving opening in the closed 'end portion of the holder.

registering with the rearward end of the bore-adjacent the periphery of the bore, a die body positioned re-' movably in the die holder and projecting forwardly there from and having a spiral passageway about its periphery registering with the wire'receiving opening in the die holder, at bearing'sleeve mounted freely within the hous- I ing adjacent the forward end of the dieholder and freely Lever 70 on cam 62 1s elevated to allow spring '80 to forming an axial extension of the opening in the bearing sleeve, drive means on theframe for forcing wire through the wire receiving opening and thespiral passageway in the die body, clutch means in 'saiddrive means for controlling operation of the latter, movable link means on the frame and engaging the clutch means for moving drive wheels 44, 46 on the drive shafts are driven at equal, substantiallyuniform rates and force the wire through the die, where it is formed into a spiral having a pitch'determined by the pitch of the channels on the As the first spiral is formed, it extends outwardly from the apparatus and is suitably supported. Its: length is determined by thesetting of gear box 96. Asdrive shaft 24 rotates, it drives shaft 94 on gear box 96 through meshing gears 90, 92. Shaft 98 of the gear box thereupon is rotated rapidly or slowly depending upon'the setting of the box. Cam 100 ontheend of shaft 98 is rotated correspondingly. Then when projection 102 on the cam contacts roller 104 on plunger 106 of electric switch 108, the switch is closed, energizing a circuit including solenoid 110. 1 7

Acting through rod 120, the solenoid moves latch 122 to the right as viewed in Fig. 1 against the compression of spring 130, until arm 126 abuts against stop 128. Cross link 150 thereuponno longer is restrained by the latch, and spring 146 acts to move arm -144fof bell crank lever 142 in a counterclockwise direction,..disengaging the clutch and elevating foot pedal l32; Hence the drive stops almost immediately, although there is sutficient the latter between engaging and disengaging. positions, manually operated levermeans on the frame connected to the link means for moving-the clutch means to engaging position, solenoid operated lock meansconnected to the link means forselectively locking the link means in' clutch-engaging position and for releasing the link I 7 means to disengage the clutch, the solenoid having an electric circuit including a switch, and switch actuating means operated synchronously by the drive means and 'operable after a predetermined operating 'cycle of the drive means to elfect release of the link means and disengagement of the clutch means.

2. Wire forming apparatus comprising a frame; die means mounted 'on the frame; a bearing sleeve rotatably mounted about the die means and in frictional engage- -ment with the wire passing therethrough; a pair of drive wheels positioned about the die means for forcing wire through the die means; drive means for the drive wheels; 2. clutch'in the drive means for controlling operation of the latter; pivotally mounted link means on the frame engaging the clutch and movable, between a'lo'cked position and a released position for holding the clutch in its engaging and disengaging positions, respectively; a manwhy. operated lever on the frame connected to thelink means for moving the link means, to its locked position;

iAfter' the {spiral has-beenrformed, it'is severed-with knife 200. It then is elevated slightly in the holding ap-- a solenoid having a movable member and an electric circuit; a' switch in the electric circuit; lock'mean's Connected "to the movable member of 1theiso1efioidend i' leasably engaging the linkmeans foi' s'cfiiiiig' the" latter in locked position, the lock means comprising a cross link pivbtally mounted on the fiame and engaging the link means, a spring pressed latch pivotally mounted on the frame and connected to 'themovabl ifi'einher of the solenoid, the latch being engageable with the cross link upon movement of themamially operated lever to lbclied position, the latch beingdisengage'able from the cross link upon movement of the'rnovabl member of the solenoid to unlocked position, thereby releasing the linli means for movement to di's'engagethe clutch; and a' cam' driven synchronously by the drive means, the can being arranged to engage the switch at the completion of a Wire forming cycle to move the movable member of the solenoid and release the link means from its locked position, thereby disengaging the clutch.

References Cited in the fiie of this patent" UNITED STATES PATENTS 101,577 Brombacher' Apr. 5, 1870 1,115,347 Suggs Oct. 27, 1914 1,468,825 Metz Sept;'25, 1923 1,946,870 Moon Feb. 13, 1934 2,062,552 Burgess -E ec. 1, 1936 2,096,605 Blount Oct. 19, 19 37 7 2,306,224 Parker et al. Dec. 22, 1942 2324,641 Peterson July 20, 1943 2,455,863 Halvorsen D6657, 1948 2,756,803 Faebr' July 31, 1956' 

